How to Cut Grain Block Flooring

Grain block flooring uses the same cutting and assembly principles as butcher block.

Grain block flooring, also called end-grain, is a traditional material used in an uncommon way. This type of flooring uses wood tiles that are cut off the end of dimensional lumber such as two-by-fours, and the tiles are installed flat with the grain facing up. One board can yield numerous tiles. The result is a strong floor with many end-grain patterns throughout the room. Nearly any wood species is appropriate for end-grain flooring, from oak and poplar to pine. If your miter saw doesn't have an adjustable, locking jig, you'll need to make one to ensure consistent cuts.

Fabricate a Jig

1

Set the platform of the miter saw at zero degrees, which makes a straight cut.

2

Place a two-by-four or slightly larger board on the platform, and trim off one end with a straight cut. It doesn’t matter how much material you cut off, as long as the board remains approximately 10 to 12 inches long. This cut is for straightening one end of the board.

3

Slide the board over and make another straight cut, leaving the board approximately 8 inches long. The precise length of the board is not critical, as the scrap will be used as a miter saw cutting jig. Jigs help you make numerous cuts in a nearly identical way without measuring and marking repeatedly.

4

Measure over 1 inch to the right of center on the miter saw platform. Make a light pencil mark on the platform or back fence of the saw at the 1-inch spot. If the fence has measurement markings, you can use those instead of marking the saw with a pencil.

5

Set the scrap board flat on on the platform and align the left end of the board with the pencil mark or 1-inch mark on the fence. The remainder of the board should extend out to the right.

6

Open two C-clamps or ratcheting wood clamps and slip them down over the back fence and the scrap board together. The clamps should be far enough away from the path of the saw blade to not interfere with its operation.

7

Tighten the clamps to hold the board firmly against the fence. Alternatively, if your saw fence has screw hole openings, you can drive wood screws through the back side of the fence and into the scrap board with a power drill and a Phillips driver bit.

8

Test the board to be sure the clamps or screws have rendered it immobile. If it moves, it won’t work properly as a jig; your cuts won’t be uniform. Tighten the clamps or screws if the board moves.

Cut the Tiles

1

Lay a piece of dimensional lumber that you will use for the grain block tiles on the saw platform. Use two-by-fours or larger in any wood species that you prefer. Plug in or turn on the saw, but don’t engage the blade.

2

Slide the board over until the end butts firmly against the jig that you mounted on the saw. Hold the board against the back fence, engage the blade and cut the board.

3

Raise and disengage the blade, then remove the 1-inch wood tile that you cut from the board. This is one grain block tile. Measure the tile, if desired, to check the thickness. Adjust the fence if necessary.

4

Move the board over against the jig and cut another tile. Cut the remainder of the grain block tiles the same way. Stop to check the jig periodically. If it has moved or loosened, tighten it or make a new jig. If you are making enough blocks for a very large floor, the jig may require several adjustments throughout the process.

Things You Will Need

Miter saw

Scrap board, 2-by-4-inch or larger, 12 inches long

Ruler

Pencil

C-clamps or ratcheting wood clamps

Wood screws

Power drill and Phillips bit

Dimensional lumber, 2-by-4-inch or larger

Eye protection

Tips

Make grain block tiles any thickness that you like. Tiles that are 1 inch thick raise the profile of the floor about as much as traditional wood flooring, but you can make them slightly thicker or thinner.

Any tool that allows you to cut off tiles in a uniform thickness, such as a table saw, is an acceptable replacement for a miter saw.

Cutting the grain block tiles at a consistent thickness reduces the amount of sanding required to finish the floor.

Grain block tiles are usually installed by spreading polyurethane glue on the floor with a notched trowel, and pressing the tiles into the glue. Unlike a ceramic tile installation, grain block tiles are butted together and grout isn’t used. Finish the floor with varnish or polyurethane to seal out moisture and stains.

Warnings

Wear protective glasses or goggles when cutting with a miter saw.

A miter saw blade can send a small cut piece, such as the end-grain tiles, flying. To help prevent this, engage the blade and lower it to make the cut. Release the power on the blade and wait until it stops turning before raising the blade.

Cutting tiles too thin, less than 1/2 inch, makes them susceptible to breakage during installation.

About the Author

Lee Carroll, a writer based in east Tennessee, has authored numerous law and DIY home improvement articles and essays. In addition to holding a degree in paralegal studies, she has more than 10 years of experience renovating newer homes and restoring historic property.